Hydraulic System of ZJ70DBS Rig

YZ133-SC

March, 2014
 Foreword

Hydraulic system is one of the main corollary equipment of ZJ70DBS drilling rig

and can meet the drilling application of drilling rig.

This manual describes generally the technical parameters, working principle,

overall structure and component structures, installation, operation, maintenance and

repair etc of the hydraulic system. The operators of the hydraulic system shall read this

manual carefully before starting to install and operate the system.

There is a recommended spare parts list attached to this manual as a reference for

users ordering spare parts. If the spare parts needed by users are not included in the list,

please refer to the attached drawings in this manual.

There is an ex-factory SN for each component of the hydraulic system, please

point out the model and the ex-factory SN of the component when ordering the spare

parts or inquiring related things.

Contact information:

Sichuan Honghua Petroleum Equipment Co., Ltd.

Address: South section 2, Zhongshan Road, Guanghan, Sichuan

Postal code: 618300

Office telephone: 86-838-5151724

Fax: 86-838-5151100

Website: www.hhcp.com.cn

Telephone of after service department: 86-838-5152112

Telephone of home marketing department: 86-838-5101571

Telephone of foreign marketing department: 86-28-86013524

 IMPORTANT SAFETY STATEMENTS

The personnel engaged in use, management, operation, maintenance and repair of

this system shall know related contents in the manual well, follow the regulated

requirements about use, management, operation, maintenance and repair, and

especially pay attention to safety warnings and notices mentioned in this manual,

national laws and regulation, industrial regulations and general knowledge for avoiding

human injury and equipment damage.

It is not possible to list all contents of safety warnings in detail in this manual.

Therefore, choose a proper way to operate the system for avoiding human injury and

equipment damage.

To maintain the system correctly is an important way to keep it in reliable and

safe operation. The personnel engaged in maintenance shall maintain it as per the

methods introduced in this manual.

Be sure to repair the product properly and replace parts with the parts made by

their manufacturer for the safe and reliable operation of the equipment. The users must

repair and replace parts as per the manufacturer-authorized right.

Please read words with following titles or signs carefully!

Warning: used in the conditions that may cause personal injury or death due to

inconformity with operation steps and methods;

Note: used in the conditions that may cause equipment injury and or damage due

to imprecise observation of operation steps and methods.

 Contents

1. Safety warnings ........................................................................................................ 1

2. Description of HPU .................................................................................................. 2
2.1 HPU ........................................................................................................................ 2
2.2 Actuating mechanism ............................................................................................. 2
2.3 Control system ....................................................................................................... 3
2.4 Pipeline connection ................................................................................................ 3
2.5 Safety facilities ....................................................................................................... 3
3. Main performance parameters.................................................................................. 3
4. Schematic diagram of hydraulic system .................................................................. 4
5. Block diagram of hydraulic system.......................................................................... 4
6. Installation of hydraulic system ............................................................................... 5
7. Operation of hydraulic system ................................................................................. 6
7.1 Check...................................................................................................................... 6
7.2 Startup and pressure adjustment of system ............................................................ 7
7.3 Operation of hydraulic system ............................................................................... 9
8. Maintenance and troubleshooting ............................................................................. i
8.1 Hydraulic cathead................................................................................................. 12
8.2 Proportional multi-way reversing valve ............................................................... 12
8.3 Others ................................................................................................................... 14
8.4 Spare parts list of hydraulic system ..................................................................... 19
8.5 Recommended one-year spare parts list ............................................................... 20
9. Attached drawings .................................................................................................. 22

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1. Safety warnings

1.1 Only trained and qualified persons can install, operate and maintain the

hydraulic system with qualification certificates.

1.2 Persons on duty shall wear labor protection articles as required.

1.3 Fire is forbidden around the hydraulic system.

1.4 Open the oil drainage ball valve of plug pump and the oil suction valve of oil

filling pump at the bottom of oil tank before starting the hydraulic system, otherwise

the oil pump may be damaged.

1.5 Check the oil level carefully, add oil in time if the level is too low, so as to

prevent the hydraulic components of oil pumps etc from being damaged.

1.6 If there is a warning signal, stop the system operation immediately. It cannot

be started again before the problem is not solved.

1.7 Cut off power supply and release the system pressure before starting

maintaining operation. There shall be a shut-off device for wrong operation and

distinct warning board to avoid the safety accident of human injury and equipment

damage.

1.8 Do not wear gloves during maintaining operation. Oil collecting measures

shall be taken to keep the system and environment clean.

1.9 When plugging out the quick release joint, be sure to install the protection cap

on the quick release joint for avoiding pollutant getting inside. Make sure the cleanness

of joints before plugging in.

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2. Description of HPU

2.1 HPU

YZ133 HPU is specially designed and manufactured for ZJ70DBS drilling rig and

integrates machinery tools and disc brake hydraulic control. It supplies hydraulic

power to hydraulic machinery tools and hydraulic disc brake device and is also used as

the power source of other hydraulic devices.

It mainly comprises main hydraulic pump set, oil filling and circulating pump set,

general control valve set, brake pump set, brake block assembly, oil tanks and

accessories, and electric apparatus control cabinet etc.

The main control valve of the hydraulic system uses PSL-6 load sensitive

dual-control (electric/manual) proportional multi-way reversing valve bank to control

the direction, pressure and flow rate of the system, which greatly reduces the quantity

of related control elements, piping and system commissioning work, and can

simultaneously work in multi-load condition of different pressures and different flow

rates. If the electric control system cannot work normally, manual revering and control

mechanism can keep all parts work smoothly.

2.2 Actuating mechanism

It comprises left hydraulic cathead, right hydraulic cathead, hydraulic tong, BOP

lifting device, casing stabbing board, mast buffer cylinder, substructure buffer cylinder

and hydraulic disc brake device.

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2.3 Control system

The driller's control cabin is provided with PLC remote control and display

system by which automatic control of the following functions can be achieved.

2.3.1. Automatic control of oil temperature;

2.3.2. High and low liquid level warning;

2.3.3. Presetting of make-up and break-out torque of catheads;

2.3.4. Automatic halt of main motor in cause of liquid temperature limit or liquid

level limit.

2.4 Pipeline connection

Connect the HPU with all actuating elements (cathead, tong, wellhead lifting

device, buffer cylinder and disc brake) by pipeline, and install the quick release joint

which is convenient to disassemble and in favor of the disassembly and assembly of

drilling rig during moving and transportation.

2.5 Safety facilities

Safe decompression function has been designed for the hydraulic system. There

are safety warning devices for oil temperature, liquid level and pollution etc. All the

electrical components in HPU are explosion-proof. In addition, there are doorframe

with safety lock and safety warning boards.

3. Main performance parameters

Motor of machinery tool pump: power 45kW×2 rotation speed 1480r/min

Motor of circulating pump: power 1.1kW rotation speed 1450r/min

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Motor of brake pump: power 3kW×2, rotation speed 1450r/min.

Machinery tool pump: max. displacement 100ml/r

Brake pump: displacement 10ml/r

Circulating pump: displacement 50ml/r

Rated pressure of hydraulic system (disc brake/machinery tool): 8MPa/18MPa

Rated flow of hydraulic system (disc brake/machinery tool): 15L/min/120L/min

Power of heater:3KW×2

Cooler power: 3KW

Volume of oil tank: 1000L

Optimal working temperature: 35℃-55℃

Working medium:L-HM46 (Mobil DTE25) anti-wear hydraulic oil (in summer)

L-HV32 (Mobil DTE13M) low-temperature anti-wear hydraulic oil (in winter)

L-HS32 (Mobil DTE13M) low-temperature anti-wear hydraulic oil (arctic)

Cleanness of hydraulic system: NAS1638, grade 9

4. Schematic diagram of hydraulic system

Please refer to attached drawing 1.

5. Block diagram of hydraulic system

Please refer to attached drawing 2.

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6. Installation of hydraulic system

6.1 Installation of HPU

The HPU is installed near doghouse and fixed by foundation bolts.

6.2 Connection of HPU with all actuating elements

The HPU and all actuating elements (catheads, casing stabbing board, BOP lifting

device, tong, buffer cylinder and disc brake device) are connected by hydraulic

pipelines. Please refer to fig.4 for connection interfaces. Pipeline connection is as

follows:

6.2.1 Left cathead: Rodless chamber of left cathead－chamber A of left cathead;

Rod chamber of left cathead―chamber B of left cathead

6.2.2 Right cathead: Rodless chamber of right cathead－chamber A of right

cathead;

Rod chamber of right cathead―chamber B of right cathead

6.2.3 Casing stabbing board: oil inlet port of casing stabbing board—oil inlet of

casing stabbing board,

Oil return port of casing stabbing board—any one of three “machinery tool oil

return”;

Oil drain port of casing stabbing board—to oil drain block, HPU

6.2.4 Tong: Port P--tong oil inlet

Port T-any one of three machinery tool oil intakes

Oil drain port- to oil drain block of HPU.

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6.2.5 BOP lifting device Oil inlet of BOP lifting—“oil inlet of BOP”

Oil return port of BOP lifting device—any one of three “machinery tool oil

return”;

Oil drain port of BOP lifting device—to oil drain block, HPU

6.2.6 Buffer cylinder (HPU lifting and lowering): Rodless chamber of buffer

cylinder--HPU buffer cylinder chamber A

Rod chamber of buffer cylinder--chamber B of buffer cylinder of HPU;

6.2.7 Safety tongs: MP1 ―safety caliper

6.2.8 Right service caliper: MP2—right service caliper

6.2.9 Left service caliper: MP3—left service caliper

7. Operation of hydraulic system

Please refer to Fig.3 for HPU assembly, Fig.4 for operation control mechanism,

and Fig.5 for operation control indication.

7.1 Check

7.1.1 Appearance check

7.1.1.1 Check all components of hydraulic system for traumatic damage such as

apparent crash and impact etc.

7.1.1.2 Check all actuating components of hydraulic system and pipelines for

correct connection.

7.1.1.3 Check whether operation control mechanism can be stably maintained at

the neutral position and the backlash is proper or not.

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7.1.1.4 Inch the motor pump set, and check the motor for correct rotation

direction and the running components for flexible rotation.

7.1.2 Oil check

7.1.2.1 Check whether the oil level is between the specified scale marks;

7.1.2.2 Check the conformity between the brand of the added oil and the ambient

temperature.

7.1.2.3 Check the oil for muddiness and replace the hydraulic oil if any even

through the replacement period is not reached.

7.1.3 Connection check

7.1.3.1 Check the assembly and connection of all hydraulic actuating mechanisms

for correctness and reliability.

7.1.3.2 Check the connection of the quick release joints of the components for

correctness and reliability.

7.2 Startup and pressure adjustment of system

7.2.1 Startup

7.2.1.1 Check the joint and the connection of the hydraulic loop for oil leakage

and abnormality and treat if any.

7.2.1.2 Start the HPU, run for 10 minutes at idle load, and monitor all components

for abnormality.

7.2.2 Pressure regulation

7.2.2.1 Pressure regulation of master safety valve

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7.2.2.1.1 Loosen the master safety valve

7.2.2.1.2 Select any valve in the general control valve bank, use the valve to load

for pressure regulation, pull up the hose quick joint corresponding to the plate valve at

the baffle plate of the outlet of the HPU, and screw up the relief valves of the valve.

7.2.2.1.3 Start motor, operate the handle of the valve for loading.

7.2.2.1.4 Screw up the pressure regulating screw of the master safety valve,

observe the numerical value of the load pressure gauge, regulating the pressure to

18MPa, and finally screw down the nut.

7.2.2.2 Pressure regulation of single relief valve

In the same way, unscrew screw of relief valve of single valve, operation handle

of single valve and load it, and then screw the screw of relief valve in slowly to

observe reading of pressure gauge.

7.2.2.2.1 The first valve controls the mast or substructure buffer cylinder.

7.2.2.2.2 The second plate valve selects the hydraulic tong and the BOP lifting

device for oil supply. The pressures of the relief valve are 16.6MPa at port A and

16MPa at port B.

7.2.2.2.3 The third valve supplies oil to casing stabbing board and “operating

box”, the pressures of the relief valve is 16MPa.

7.2.2.2.4. The fourth valve controls the left hydraulic cathead, and the pressure of

the relief valve is 16MPa.

7.2.2.2.5. The fifth plate valve controls the left hydraulic cathead, and the pressure

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of the relief valve is 16MPa.

Note: Before delivery, system pressure had been adjusted and user can

directly use equipment.

7.3 Operation of hydraulic system

7.3.1 Installation working condition of drilling rig

Operate the first plate valve and control mast buffer cylinder (50) and substructure

buffer cylinder.

Lift mast by HPU: operate the reversing valve manually, reverse back and forth,

and check the buffer cylinder for free extension and the joints of the pipelines for

leakage. If everything is normal, operate the reversing valve of the first valve to the

'raising' position to extend the piston of the buffer cylinder, and rotate the regulating

knob of the relief valve (37) of the buffer cylinder until the numerical valve of the

pressure gauge (38.2) is 3-5MPa. When the mast is in contact with the piston of the

buffer cylinder, slowly rotate the regulating knob of the relief valve (37) of the buffer

cylinder anticlockwise until the mast is raised in place.

Lower mast by HPU: before mast lowering, loose adjustable button of HPU relief

valve (37).Operate the first plate valve to the 'lifting' position manually so that the

pressure oil enters the rodless chamber of the buffer cylinder, and simultaneously

screw down the regulating knob of the relief valve (37) of the buffer cylinder slowly,

and the pressure is raised until the mast is pushed to deviate from the center of gravity.

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(Note: at this time, the DW motor shall have suspension function, the hydraulic disc

brake of the DW is released, the mast is not fixed, and operates the control hand wheel

of the DW motor so that the drum rotate negative while extending the oil cylinder.) ）

The operation methods for lifting and lowering substructure are same as mast

lifting and lowering by HPU.

7.3.2 Machinery tool condition of drilling rig

7.3.2.1 Hydraulic/pneumatic tong

The second valve can selectively supply oil to the following actuating

mechanisms:

1) Supply oil to hydraulic tong, the pressure is 16.6MPa, flow rate is 120L/min.

2) Supply oil to the BOP lifter, the system pressure is 16MPa, and the flow rate is

120L/min.

Push the handle of the second plate valve to 'tong' position to supply oil to

hydraulic/pneumatic tong.

Operate the second valve handle to the position of BOP, and oil supply of BOP

hoisting device is achieved.

7.3.2.2 The third valve can selectively supply oil to the following actuating

mechanisms:

Operate the third valve handle to the position of "casing stabbing board", and oil

supply of the casing stabbing board is achieved. The pressure is 16Mpa and flow is

120L/min.

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“Operation box” of the third valve is used as oil source of standby port. The

pressure is 16MPa and flow is 120L/min.

7.3.2.3 Hydraulic cathead

The fourth plate valve controls the right hydraulic cathead, the fifth plate valve

controls the left hydraulic cathead, the working pressure of the oil ports of the chamber

A of the right cathead and the chamber A of the left cathead is 0-16MPa and given by

the proportional relief valve 27, and the flow rate is 120L/min.

The hoses of the rodless chambers of the oil cylinders of the left and right

catheads are respectively with the ports of the chamber A of the left cathead and the

chamber A of the right cathead, and the hoses of the rod chambers are respectively

connected with the ports of the chamber B of the left cathead and the chamber B of the

right cathead. The extension and retraction of cathead cylinder can be achieved by

controlling electromagnet YV5 and YV6 of the fourth valve bank and electromagnet

YV7 and YV8 of the fifth valve bank in driller’s control cabin. The extension and

retraction of the cylinders of the right cathead and the left cathead can be controlled by

manually operating the handles of the fourth and the fifth valve banks.

Pull tong by the wireline connected to hydraulic cathead to perform make-up or

break-out operation on DP, drilling collar and casing.

The neutral sliding valve mechanism of the fourth and fifth valve sets are L type

and oil cylinder is locked with the sliding valve is at neutral position.

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Notice: the torque regulation of cathead is achieved by proportional relief

valve 27. Close stop valve 29 when torque of cathead is regulated manually.

7.3.2.4 Hydraulic disc brake unit

User manual is attached additionally.

8. Maintenance and troubleshooting

Warning: stop motor pump, cut off power supply and release pressure

in maintenance and troubleshooting.

8.1 Hydraulic cathead

User manual is attached additionally.

8.2 Proportional multi-way reversing valve

PSL type proportional multi-way reversing valve is used for controlling the

movement direction of hydraulic actuating components and can regulate their

movement speeds in a stepless way and enable many actuating components to work

simultaneously at different pressures and speeds without mutual interference. The

control by using PSL type proportional valve is advanced technique in hydraulic field

and has complete functions, good performances, stable quality and high precision etc.

But in practical application, if it is not installed or used as required, some faults may be

caused.

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8.2.1 No system pressure

8.2.1.1 When operating one of the valves, the system has no pressure, and if other

plate valves work normally, the plate valve goes wrong, and remove the troubles by

mainly adopting the following steps:

8.2.1.1.1 First check the pipeline and oil cylinder connected to the plate valve for

faults.

8.2.1.1.2 Check the secondary pressure regulating valves at ports A and B for

blockage due to insufficient cleanness of oil.

8.2.1.1.3 Check the two-way regulating valve in plate valves for blockage.

8.2.1.2 If any of the plate valves works and there is still no pressure, the

connecting block goes wrong, and remove the trouble by mainly adopting the

following measures:

8.2.1.2.1 Check three-way flow regulating valve for blockage or the damping

screw in valve core for blockage.

8.2.1.2.2 Check whether the master relief valve is blocked and cannot be closed

due to scrap iron.

8.2.2 Manual operation is normal, but electric operation has no response.

Check circuits for wrong connection and current input. If the circuits are correct,

check coil for burned damage, in addition, too low pressure of hydraulic system

control loop may also cause above phenomena.

8.2.3 Oil cylinder or motor vibrates or crawls in operation.

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Air existing in system may cause this phenomenon and the system recovers after

air is exhausted completely. In addition, as structural components is unbalanced in

stress in the moving process, the actuating component (oil cylinder or motor) is lower

is manufacturing precision or has inside leakage, thereby causing vibration or crawl.

Beside improvement of above factors, the influence can be removed by adjusting

damper of valve and valve core structure etc.

8.2.3.1 Replace the vibration damping component in connecting block, namely,

replace standard damper with G-type damper.

8.2.3.2 Replace valve core, namely, replace the original common valve core with

valve core with damper, or enable oil cylinder or motor to generate 20bar back

pressure in movement.

8.2.4 Spring cover in valves deforms and leaks oil.

It is caused by too high oil drainage pressure (above 10bar).Generally, check the

oil drainage port T in terminal block for correct connection and connecting pipelines

for blockage etc.

8.2.5 Valve lever is operated inflexibly with blockage and non-return phenomena.

It may be caused as oil is not clean sufficiently; therefore, the valve lever is worn

or blocked.

8.3 Others

8.3.1 Hydraulic oil

Frequently check level in oil tank and supplement oil in time. When the level in

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the oil tank is below the minimal level, the temperature rise, accumulation of insoluble

air failure of pump due to cavitation and local temperature rise due to exposure of

electric heater may be caused. Therefore, oil goes bad and system faults are caused. If

level decreases, it indicates that there are places which impregnate and leak oil, check

and repair in time.

Hydraulic oil is divided into oil for summer and winter in principle and replaced

once six months.

8.3.2 Oil temperature

The optimal working temperature of hydraulic oil is 35℃-55℃, and too high

temperature can quicken the ageing of the oil and shorten the service life of sealing

members and hoses. The oil temperature in oil tank must be monitored frequently.

Gradual temperature rise shows that there is pollution or colloid formation or plunger

pump wear. When oil temperature is raised suddenly, stop and check machine.

When oil temperature is lower than 10℃, start heater, and when oil temperature is

higher than 35℃, stop heater. When oil temperature is higher than 60℃, start

air-cooled radiator, and when oil temperature is lower than 50℃, stop radiating heat.

When oil temperature is raised to 80℃, alarm and stop for check.

Notice: when the heater or the radiator is started, start the circulating

pump motor simultaneously.

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8.3.3 Oil filter

The filter elements of oil suction and oil return filters are replaced once three

months.

Air filter is only used for filtering air coming in and out oil tank when liquid level

in oil tank is raised or lowered. Check, clean or replace filter elements once 1-3

months.

8.3.4 Utilized pump

Detect pump set and maintain pump set in good working status without abnormal

temperature rise and abnormal sound.

8.3.5 Quick release joint

Check for falling, abnormal damage and oil leakage etc.

Maintenance schedule

Maintenance
No. Contents Requirements
period

Keep the oil level in the scope between

1 Liquid level
maximum and minimum levels.

Optimal working Every shift

2 33℃-55℃
temperature

3 System pressure 8MPa / 18MPa

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Running sound and

4 temperature of utilized No abnormal noise and high temperature

pump

5 Sealing of oil cylinder No drop leakage

6 All pipelines and joints Good sealing without leakage and damage
Every day
No leakage, damage and virtual
7 Quick connector
connection

Check and fasten all fixing bolts and

8 All fixing bolts Every week
screws.

9 Oil sample Clean and transparent 6 months

10 Filter element Replace 3 months

8.3.6 Troubleshooting

Some potential fault phenomena, reasons for faults and troubleshooting methods

are given out in the following list for reference in maintenance.

Trouble
Reasons Troubleshooting
phenomena

Blockage of oil supply filter element Replace filter element

Improper
Too low liquid level in oil tank Fill oil to liquid level line
system
Clean oil tank and replace
pressure Pollution of hydraulic oil and dirty oil
hydraulic oil

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Cut-off valves on oil suction and oil Open cut-off valve at

return pipelines of pump are not opened. bottom of oil tank

Cut off power supply of

Power supply of heater is not cut off
heater

Too high oil Blockage of oil suction filter element Replace filter element

temperature Too low liquid level in oil tank Fill oil to liquid level line

Clean oil tank and replace

Pollution of hydraulic oil and dirty oil
hydraulic oil

Blockage of oil filter element Replace filter element

Too low liquid level in oil tank Fill oil to liquid level line

High noise Air in system due to looseness of oil

Check and fasten
or vibration suction and oil return pipe joints

Motor and pump shaft are not centered. Re-center and install

Looseness of base bolt of motor Check and fasten

Check relief valve and

Too low system pressure
regulate pressure again

Inflexible Blockage of oil suction filter element Replace filter element

hydraulic Control valve is blocked or has defect or Check, clean or replace

operation leaks seriously. valve

Check or replace sealing

Actuating mechanism leaks seriously.
members

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8.4 Spare parts list of hydraulic system

No. Description Spec. Qty. Remarks

1 Combined sealing washer 8 2 JB982-77

2 Combined sealing washer 10 10 JB982-77

3 Combined sealing washer 12 10 JB982-77

4 Combined sealing washer 14 10 JB982-77

5 Combined sealing washer 16 2 JB982-77

6 Combined sealing washer 22 5 JB982-77

7 Combined sealing washer 33 10 JB982-77

8 Pressure test joint PT-3 1

9 Pressure test joint PT-7 1

10 O-ring 90×3.1 2 GB1235-76

11 O-ring 75×3.1 2 GB1235-76

12 O-ring 65×3.55-A-S 4 GB/T3452.1

13 O-ring 70×3.5 3 GB1235-76

14 Quick release joint INT-NPT1/4-GMF 2

15 Quick release joint INT-NPT3/8-GMF 1

16 Quick release joint INT-NPT1/2-GMF 1

17 Quick release joint INT-NPT3/4-GMF 2

18 Quick release joint INT-NPT1-GMF 1

19 Nitrogen charging tool CQJ-10 1

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YN-60- Ⅲ ;
20 Shockproof pressure gauge 1
0-25Mpa
YN-60- Ⅲ ;
21 Shockproof pressure gauge 1
0-16Mpa

22 Shockproof pressure gauge YN-60-Ⅲ; 0-4Mpa 1

23 O-ring 90×3.1 2 GB1235-76

24 Sealant 1567 1

8.5 Recommended one-year spare parts list

No. Description Spec. Qty. Remarks

1 Three-way ball valve KHN3K-G1-T-2233 1

2 Ball valve Q11F-25-G1/4 2

3 Shockproof pressure gauge YN60-Ⅲ:0~25MPa 2

4 Shockproof pressure gauge YN60-Ⅲ:0~16MPa 2

5 Pressure transmitter KYB18G-HX (0~35MPa) 1

Hydraulic control reversing

6 3WH6B53 1
valve

7 Pressure transmitter KYB18G-HX(0~10MPa) 1

Ex-proof electromagnetic MFH-3-1/4-TT45-SA+M

8 1
reversing air valve SFG-24-EX-SA

9 Pressure test joint PT-3 1

10 Pressure test joint PT-7 1

11 Pressure test hose HFH2-P1-3-P-3.0 2

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12 Check valve RVP16-10 1

13 Air filter QUQ3-10X4.0 2

PXA4ML-2.5/10bar-1/4"-

18NPT inner

thread-1/2\U+201C-14NP
14 EX-proof pressure switch 1
T inner thread; Contact

closing pressure is

0.4MPa.With cable of 3m

15 EX-proof electric heater SJB2-3 2

16 Quick release joint INT-NPT3/8-GMF 5

17 Quick release joint INT-NPT3/4-GMF 10

18 Quick release joint INT-NPT1-GMF 5

Machinery tool pump oil

19 TFX-400X100 2
suction filer element
Disc brake pressure pump oil
20 HX-25x10 2
suction filer element
Machinery tool high pressure
21 HX-250x20 2
pump oil suction filer element
Disc brake pump oil suction
22 TFX-63x100 2
filer element

23 Oil return filter element FBX-400X10 2

Oil pump oil suction filer

24 IX-160X100 2
element
Disc brake oil return filer
25 FAX-63x10 2
element

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PCA2MA-20/100bar-1/4″
EX-proof pressure switch
-18NPT inner
26 (contact closing pressure 1
thread-1/2″-14NPT inner
6.5MPa)
thread; With cable of 3m

9. Attached drawings

9.1 Fig.1 Schematic diagram of hydraulic system

9.2 Fig.2 Block diagram of hydraulic system

9.3 Fig.3 Assembly drawing of HPU

9.4. Fig.4 Drawing of operation control mechanism

9.5. Fig.5 Operation control indicator diagram

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1 Liquid level gauge 32 Quick release joint

2 Ex-proof temperature sensor 33 Quick release joint

3 Ex-proof liquid level controller 34 Quick release joint

4 EX-proof electric heater 35 Quick release joint

5 Air filter 36 Pressure gauge

6 Ball valve 37 Relief valve

7 Ball valve 38 Pressure gauge

8 Ball valve 39 Pressure test joint

9 Three-way ball valve 40 Oil return filter

10 Oil return filter 41 Oil suction filter

11 Oil suction filter 42 Plunger pump

12 Ex- proof motor and oil pump combo 43 Ex-proof electric motor

13 Oil suction filter 44 Check valve

14 Gear pump 45 Relief valve

15 Explosion -proof electric motor 46 High-pressure filter

16 Ex-proof electromagnetic change valve 47 Ball valve

17 Check valve 48 EX-proof pressure switch

18 Pressure sensor 49 Accumulator

19 High-pressure filter 50 Ex-proof electromagnetic change valve

20 EX-proof pressure switch 51 Ex-proof proportional amplifier board

21 Pressure test joint 52 EX-proof proportional relief valve

22 Pressure test hose 53 Mis-operation protection valve

23 Pressure gauge 54 Relay valve

24 One-way throttle valve 55 Electromagnetic directional air valve

25 Air cooler 56 Pneumatic reversing valve

26 Check valve 57 Hydraulic control reversing valve

27 Relief valve 58 Pressure sensor

28 Check valve

29 Ball valve
Fig.1 Schematic diagram of hydraulic system 30 Multiple reversing valve

31 Quick release joint

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User Manual of Hydraulic System

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1 Polyurethane tube 32 Pressure gauge 64 Hose assembly

2 Quick connector 33 Ex- proof motor and oil pump combo 65 EX-proof pressure switch

3 Quick connector 34 Hose assembly 66 General control valve bank

4 Remote control device 35 Hose assembly 67 Pump valve control device

5 Hose assembly 36 Hose assembly 68 Hose assembly

6 Cutting ferrule joint 37 Brake block assembly 69 Hose assembly

7 Air cooling device 38 Disc brake pump set 70 Hose assembly

8 Hose assembly 39 Stainless steel tube 71 Hose assembly

9 Cutting ferrule joint 40 Cutting ferrule joint 72 Hose assembly

10 Cutting ferrule joint 42 Spring washer 73 Hp filter set

11 Cutting ferrule joint 43 Spacer 74 Inner hexagon cheese head screw

12 Nameplate 44 Clamp plate 75 Spring washer

13 Hose assembly 45 Bolt 76 Hose assembly

14 Tag plate of max. liquid level 46 Gasoline pump set 77 Plug

15 Tag plate of max. liquid level 47 Oil suction filter 78 Cutting ferrule joint

16 HPU warning board 48 Hose assembly 79 Hose assembly

17 Half-round head rivet 49 One-way throttle valve 80 Skidding operation box

Maintenance nameplate of disc

18 brake system 50 Pressure test joint 65 EX-proof pressure switch

19 Comprehensive oil tank assembly 51 Miniature high pressure hose

20 Framework 52 Cutting ferrule joint

21 Split flange 53 Cutting ferrule joint

22 Inner hexagon cheese head screw 54 Cutting ferrule joint

23 Spring washer 55 Flange, gasoline filter

24 Hose assembly 56 O-ring

25 Hose assembly 57 Stainless steel tube

26 Split flange 58 Quick release joint

27 Hose assembly 59 Stainless steel tube

28 Inner hexagon cheese head screw 60 Quick release joint

Fig.3 Assembly drawing of HPU 29 Spring washer 61 Cutting ferrule joint

30 Pressure gauge 62 Hose assembly

31 Pressure gauge 63 Oil drain block assembly

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 User Manual of Hydraulic System

Fig.4 Drawing of operation control mechanism

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 User Manual of Hydraulic System

Fig.5 Operation control indicator diagram

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